High purity starch stream methods and systems

ABSTRACT

Methods and systems for isolating a high purity starch stream are provided. The methods provide an initial treatment step in advance of traditional grinding or fractionation operations (such as dry milling or wet milling operations) that facilitate separation of starch from other components of starch-based grains, for example facilitate separation of soft endosperm from other components of corn kernels including hard endosperm. The systems include a first treatment system for separating a high purity starch stream from other components of the grain stream, wherein the system can be configured as a bolt on for traditional milling operations such as wet milling and dry milling operations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional Patent Application of nonprovisionalpatent application Ser. No. 14/983,320, filed Dec. 29, 2015, titled HIGHPURITY STARCH STREAM METHODS AND SYSTEMS, which claims the benefit ofU.S. Provisional Application No. 62/098,654, entitled, “HIGH PURITYSTARCH STREAM METHODS AND SYSTEMS”, and having a filing date of Dec. 31,2014, wherein the entireties of each of the nonprovisional applicationand the provisional applications are incorporated by reference.

FIELD

The specification generally relates to methods and systems for producinga slip stream of starch, such as a high purity slip stream of starch, inethanol fermentation facilities. The specification also relates in partto methods and systems for producing a slip stream of starch, forexample for the production of non-ethanol chemicals, in ethanolfermentation facilities with little to no impact on the ethanolfacility's alcohol yield. This specification also relates in part tomethods and systems for improving the economics of corn-to-ethanolfermentation processes.

BACKGROUND

The demand for renewable fuels and chemicals has been growingsignificantly over the last years to reduce reliance on petroleum. Atthe same time, interest in biofuels, such as ethanol, as an alternativeto petroleum has greatly increased, in part due to the desire to promotedomestic rural economics. Ethanol is the most commonly used biofuel, andcurrent U.S. biofuel is almost exclusively derived from corn. However,economics is an obstacle to widespread adoption of biofuels.

Conventional ethanol fermentation facilities produce ethanol fromstarch-based feedstock such as corn. In a typical conventionalcorn-to-ethanol fermentation process, starch present in corn is brokendown into simple sugars, which can be fermented by an ethanologen suchas yeast into ethanol. An approach that has been taken to improve theeconomic viability of starch-based corn ethanol production is to makeother components of corn available to sell. More specifically, someconventional processes use a wet mill rather than dry millcorn-to-ethanol approach.

In dry milling, whole kernels of corn are ground to produce a singlestream of whole ground corn for the corn ethanol conversion process. Bycontrast, in wet milling, corn is steeped—soaked in water to soften thegrain and facilitate separating the various components of the cornkernel—to produce separate streams of starch, fiber and germ. Whereasthe starch stream is used in the corn ethanol conversion process, thefiber and germ streams may be separately processed into other products.

While wet milling processes provide a cleaner separation betweenendosperm, bran, and germ as compared to dry milling processes, it is avery capital intensive process that requires numerous pieces ofequipment in order to produce a high purity starch stream. On the otherhand, while dry milling processes are considerably less expensive thancomparable capacity wet milling processes, dry milling processes do notprovide the stream purity that may be desirable for some downstreamprocesses. Whole corn grinding creates a corn flour from the entire cornkernel that is too comingled with bran and germ to allow separation of ahigh starch stream.

SUMMARY

The present disclosure relates in part to methods and systems forproducing both a starch stream for the production of non-ethanolchemicals (“bio-chemicals”) as well as a starch stream for theproduction of ethanol in ethanol fermentation facilities whilemaintaining a commercially-acceptable ethanol titer. In someembodiments, the dual bio-chemical and ethanol starch streams areproduced while essentially maintaining the same ethanol titer as couldbe produced by the same facility if it did not produce the bio-chemicalstarch stream. In some embodiments, the present disclosure providesmethods and systems for producing a starch stream, for example a highpurity starch stream, in the context of any of the above-mentionedmilling scenarios, and which can be installed as initial method steps orsystem components in those milling scenarios.

In some embodiments, methods according to this disclosure compriseproducing from a starch-based stream such as a corn stream, a firsthigh-starch stream comprising at least about 88% starch on a dry basisand a second feedstock stream which is suitable for further processingin a dry mill or wet mill (such as a corn dry mill or corn wet mill)operation. In some embodiments, the high-starch stream comprises atleast about 90% starch on a dry basis. In some embodiments, thehigh-starch stream comprises at least about 94% starch on a dry basis.In some embodiments, producing comprises processing corn kernels in amanner that facilitates separating at least a portion of the starch fromthe remaining stream based on size. In some embodiments, the size of theat least portion of the starch is about 500 microns or less. In someembodiments, the size of the at least portion of the starch is about 260microns or less.

In some embodiments, methods according to this disclosure compriseproducing from a corn stream a first high-starch stream comprising softendosperm and at least about 88% starch on a dry basis and a secondfeedstock stream comprising hard endosperm and which is suitable forfurther processing in a corn dry mill or wet mill operation; theproducing step comprises processing corn kernels in the corn stream tofacilitate separation of at least a portion of the soft endosperm fromthe corn stream. In some embodiments, the high-starch stream comprisesat least about 90% starch on a dry basis. In some embodiments, thehigh-starch stream comprises at least about 94% starch on a dry basis.

In some embodiments, processing results in at least a portion of thesoft endosperm having a sufficiently small enough size that it can beseparated from the corn stream by its size. In some embodiments, thesize is about 500 microns or less. In some embodiments, the size isabout 260 microns or less.

In some embodiments, the process further involves producing ethanol fromthe feedstock stream in a starch-based (e.g. corn) fermentation process.In some embodiments, in order to compensate for removal of starch (suchas soft endosperm) from the feedstock stream, producing ethanol involvesusing a higher grind rate than a similar conventional starch-based (forexample corn) fermentation process using grain-based starch feedstock(e.g. whole corn kernels) would use. In further embodiments, the processinvolves removing at least a portion of the additional non-starchcomponents present as a result of the increased grind rate to achieve aratio of fermentable to non-fermentable components that is sufficientlyequivalent to a similar conventional starch-based (e.g. corn)fermentation process using grain-based starch feedstock (e.g. whole cornkernels) to maintain ethanol production at the level of the similarstarch-based (e.g. corn) fermentation process.

In some embodiments, the disclosure provides a starch-basedgrain-to-ethanol fermentation system comprising a dry mill or wet millethanol fermentation system which produces beer from feedstock sugarsderived from a feedstock stream; and, a bolt-on pretreatment systemconfigured to produce a first starch stream for producing feedstocksugars and a second, high purity starch stream, both of which arederived from the feedstock stream. In some embodiments, the high puritystarch stream comprises at least about 88%, or at least about 90%, or atleast about 94% starch on a dry weight basis. In some embodiments, thebolt-on pretreatment system is configured to facilitate separation ofstarch in the feedstock stream into a feedstock starch stream and a highstarch stream based on size.

In some embodiments, the starch-based grain-to-ethanol fermentationsystem is a corn-to-ethanol fermentation system comprising a dry mill orwet mill ethanol fermentation system which produces beer from feedstocksugars derived from a feedstock stream comprising hard endosperm; and, abolt-on pretreatment system configured to produce the hard endospermfeedstock stream and a high purity starch stream derived from softendosperm, wherein the high purity starch stream comprises at leastabout 88%, or at least about 90%, or at least about 94% starch on a dryweight basis. In some embodiments, the bolt-on pretreatment system isconfigured to mill the initial feedstock in a manner that facilitatesseparating hard endosperm stream from soft endosperm based on size.

In further embodiments, one or more bio-chemicals are produced from thehigh-starch stream. In other embodiments, ethanol is produced from thefeedstock stream. In some embodiments, the high-starch stream comprisesup to about 50% of the soft endosperm in the corn kernels.

The identified embodiments are exemplary only and are thereforenon-limiting. The details of one or more non-limiting embodimentsaccording to the disclosure are set forth in the accompanying drawingsand the descriptions below. Other embodiments according to thedisclosure should be apparent to those of ordinary skill in the artafter consideration of the present disclosure.

DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic illustration of the components of a corn kernel.

FIG. 2 is a process flow diagram of an embodiment of a method accordingto this disclosure.

DETAILED DESCRIPTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as is commonly understood by one of ordinary skillin the art to which this disclosure belongs. In the event that there isa plurality of definitions for a term herein, those in this sectionprevail unless stated otherwise.

Wherever the phrases “for example,” “such as,” “including” and the likeare used herein, the phrase “and without limitation” is understood tofollow unless explicitly stated otherwise.

The terms “comprising” and “including” and “involving” (and similarly“comprises” and “includes” and “involves”) are used interchangeably andmean the same thing. Specifically, each of the terms is definedconsistent with the common United States patent law definition of“comprising” and is therefore interpreted to be an open term meaning “atleast the following” and also interpreted not to exclude additionalfeatures, limitations, aspects, etc.

The term “about” is meant to account for variations due to experimentalerror or to permit deviations from the measurements that don'tnegatively impact the intended purpose. All measurements or numbers areimplicitly understood to be modified by the word about, even if themeasurement or number is not explicitly modified by the word about.

The term “substantially” is meant to permit deviations from thedescriptive term that don't negatively impact the intended purpose. Alldescriptive terms are implicitly understood to be modified by the wordsubstantially, even if the descriptive term is not explicitly modifiedby the word substantially.

Where ever the terms “a” or “an” are used, “one or more” is understoodunless explicitly stated otherwise or such interpretation is nonsensicalin context.

Where ever the text refers to extracting, separating, purifying or thelike, it is understood that the action may not result in a completeextraction, separation or purification. Likewise, the term “purify” andthe like does not mean 100% pure but rather only that the target productis not part of the same original mixture in which it is found. Thus forexample, the phrase “separating soft endosperm from the remainingcomponents of the corn” and the like means “separating at least aportion of the soft endosperm” even where “at least a portion” is notexplicitly stated. Accordingly, “the remaining components of the corn”includes the portion of soft endosperm that was not removed.

The term “bio-chemical” means a non-ethanol chemical made from sugarderived from feedstock that can be used in a feedstock-to-ethanol (suchas corn-to-ethanol) production process.

The phrase “high starch” or “high purity starch” or the like means atleast 88% starch on a dry weight basis. In some embodiments, the highpurity starch has a starch content of at least 90% on a dry weightbasis. In some embodiments, the high purity starch has a starch contentof at least 94% on a dry weight basis.

The term “producing” or the like means “producing directly orindirectly” unless explicitly stated otherwise or nonsensical incontext. For example, “producing a bio-chemical from starch” includesproducing the bio-chemical in a multi-step process wherein starch wouldbe the feedstock and there may be one or more intermediate steps priorto producing the desired bio-chemical.

Conventional ethanol production processes typically involve five basicsteps: milling, cooking, saccharification, fermentation, distillationand recovery. In some such processes, the milling step is a dry millingstep in which corn is ground into flour producing a whole ground cornfeed stream. In other such processes, the milling step is a wet millingstep in which corn is soaked in water producing a starch feed stream forcorn ethanol conversion and separate germ and fiber streams forindependent processing. Cooking may involve mixing the feed stream (e.g.flour) with water to form a slurry, heating the slurry to above thegelatinization temperature of the corn, and treating the slurry with aliquefying enzyme to hydrolyze starch contained therein to dextrins. Inthe saccharification step, enzymes are added to the mash to convert thecorn starch into simple sugars. The fermentation of the sugars by anethanologen such as yeast produces a beer, which is separated intoethanol and whole stillage by distillation. The whole stillage may besubject to further processing wherein it is separated into wet cake andthin stillage. The thin stillage passes through evaporators to produce asyrup, which may be recombined and dried with the wet cake to producedistillers grains with soluble (DDGS), an animal feed. Not allnon-starch-based ethanol production processes involve all the identifiedsteps. For example, in some such processes, saccharification andfermentation are not independent steps but occur simultaneously. Asanother example, some processes do not involve a cooking step.

A co-pending application entitled “Economic Ethanol Fermentation SugarStream, Process and Systems of Producing Same” by Steven Redford andassigned to POET Research, Inc. relates to production of a slip streamof sugar, for example for the production of bio-chemicals, and isprimarily directed at feedstock-to-ethanol fermentation processes thatinvolve separate saccharification and fermentation steps (although insome embodiments, the approach may be implemented in simultaneoussaccharification and fermentation (“SSF”) processes). The methods andsystems described herein relate to production of a slip stream of starch(which can be further processed into sugar and bio-chemicals) and isprimarily directed at starch-based feedstock-to-ethanol fermentationprocesses (such as corn-to-ethanol processes) that involve SSF, althoughhere again the approach is more broadly applicable, including toprocesses involving separate saccharification and fermentation steps.

In some embodiments, the present disclosure relates to methods andsystems for producing a slip stream of starch, such as a high purityslip stream of starch, in the context of starch-based grain (for examplecorn) milling operations, which may further be a part of a starch-basedgrain ethanol (e.g. corn ethanol) and/or bio-products facility. In someembodiments, the methods and systems according to the present disclosuremay be “bolted on” to (attached to) existing starch-basedgrain-to-ethanol (such as corn-to-ethanol) fermentation processes andfacilities as preliminary process steps or system components. Forexample, the methods and systems may be bolted on to existingcorn-to-ethanol fermentation processes and facilities in advance of theexisting (dry or wet) mill processes or components. Because the slipstream of starch is produced in advance of saccharification andfermentation (in fact the starch stream may be produced in advance ofconventional starch-based grain-to-ethanol (e.g. corn-to-ethanol)milling operations), the methods and systems according to thisdisclosure may be implemented in ethanol facilities in whichsaccharification and fermentation are performed either simultaneously orindependently.

In some embodiments, the starch slip stream may be further processedinto sugar, on-site or off-site (or partly on-site and partly off-site).In some further embodiments, the resultant sugar may be used asfeedstock for production of one or more bio-chemicals (also on site oroffsite or combinations thereof).

Referring now to the figures, wherein like reference numerals indicatelike elements, as shown in FIG. 1 , a corn kernel 100 comprisesendosperm 10, germ 20, pericarp 30 and a tip cap 40. Also as shown, theendosperm 10 component of the corn kernel comprises about 82% of thekernel by weight and is made up of both hard 11 and soft endosperm 12.The present disclosure provides methods and systems for producing afirst portion of starch having a sufficiently different average sizefrom remaining components of the grain (including a sufficientlydifferent average size from a second portion of starch) to facilitateremoving the first portion of starch from remaining components usingsize separation techniques. In some embodiments, the present disclosureprovides methods and systems that target and exploit the difference inthe soft and hard endosperm for deriving a slip stream of starch, forexample in the context of corn milling and/or corn fermentationprocesses. In some embodiments, the present disclosure provides methodsand systems for reaching a high purity starch stream. The disclosureprovides methods and systems that may isolate a high purity starchstream.

FIG. 2 is a process flow diagram illustrating an embodiment of a methodfor isolating a high purity starch stream in accordance with thisdisclosure. As shown in FIG. 2 , the method 200 begins at the startblock 202, wherein whole shelled corn is introduced for processing. Insome embodiments, the corn may first be cleaned and possibly moistureadjusted using traditional tempering and drying techniques, for exampleto improve bran coat removal. In some embodiments, the corn may also betemperature adjusted using traditional means.

At block 204, the grain is subjected to an initial treatment configuredto produce a treated stream, which facilitates separation of at least aportion of the starch from the remaining components of the corn. In theillustrated embodiment, the kernels are subjected to an initialtreatment configured to produce a treated stream, which facilitatesseparation of at least a portion of the endosperm from other componentsof the kernel. In some embodiments, the treatment is configured toproduce a treated stream, which facilitates separating soft endospermfrom the remainder of the stream (from hard endosperm and othercomponents of the corn).

In some such embodiments, the treatment is a milling procedure whichresults in reducing at least a portion of the soft endosperm to a sizethat is sufficiently smaller than the remaining components in thetreated stream such that the portion may be separated from the rest ofthe treated stream by size. For example, in some embodiments, thetreatment may be a light milling procedure resulting in a treated (or inthis case “milled” stream), which light milling procedure is targeted toreduce up to 50% of the soft endosperm in the incoming corn stream to afine flour which could be separated from the rest of the milled streamby size. In some such embodiments a pin mill may be used to cause thesoft endosperm, for example up to 50% of the soft endosperm, to crumbleinto a fine flour having a particle size of about 500 microns or less.

After the initial treatment step 204, the treated stream is sent to afirst separation step 206, which separates at least a portion of thestarch in the incoming treated stream from the remaining components ofthe treated stream. In embodiments wherein the separated starch isderived from soft endosperm, such as the above-described light millingprocedure, the separated starch stream is a high starch streamcomprising at least 88% starch on a dry basis. In some embodiments, theinitial treatment step, such as the initial impact or grinding step,produces a high purity starch stream comprising at least about 90%starch on a dry basis. In some embodiments, the high purity starchstream comprises at least about 94% starch on a dry basis. As a personof skill should understand, the purity of the separated starch isdependent on how commingled the starch is with non-starch components. Insome embodiments, the purity level of the starch is inversely related tothe amount of starch removed; when smaller quantities are removed,purity levels of 94% or greater can be achieved with higher quantitiesof starch removal driving down the purity. In some embodiments, the slipstream of starch, such as the high purity slip stream of starch, may befurther refined to enhance the starch percentage.

In some embodiments, the first separation step 206 is a multi-stepprocess wherein a high starch stream is separated from the main groundcorn steam (“treated” stream or “milled” stream) in one sub-step 206 a,and one or more other non-starch components are separated out in one ormore additional sub-steps. In the illustrated embodiment, fiber isseparated out from the main ground corn stream in a separate sub-step206 b. In either case, because the first treatment 204 is configured tofacilitate separation of endosperm from other components of the kernel,in some embodiments, typical separation techniques can be used to removethe high purity starch stream. For example, where a pin mill has beenused resulting in the soft endosperm crumbling into a fine particle size(or “dust”) relative other components of the stream, typical sizeseparation techniques may be used to remove the portion of softendosperm in the form of a high purity starch dust from the rest of thestream.

As a more specific example of the initial treatment step 204 andseparation step 206 the initial treatment 204 may involve grinding thecorn through a pin mill such as a Sturtevant Model 6A Pin Mill. The pinmill may be set to a specific speed typically with a tip speed of 15000fpm. The pin mill may be fitted with two rows of rotor pins and one rowof stator pins to give a desired breaking action to the corn kernels.The pin mill may also be equipped with a corrugated liner to aid withthe breaking intensity. As the ground material exits the pin mill, itmay be subjected to a sifting to separate larger particles from smallerparticles. The sifter may be any of the normal gyratory gravity sifterssuch as the Great Western Model 431, although other reciprocating orturbo type sifters could be used. In one example the ground corn stockcan be sifted through a 260 micron screen to obtain a high starch streamthat is greater than about 90% starch. The ground stock that flows overthe 260 micron screen is directed to downstream processes or to furthersize reduction processes.

In some embodiments, the separated starch stream (e.g. the high starchstream) may be further processed (on and/or off-site) into sugar and/orone or more bio-chemicals, and the remaining components of the treatedstream may be used as feedstock for a corn-to-ethanol fermentationprocess. For example, the remaining components of the treated stream maybe used as feedstock for a dry mill or wet mill corn-to-ethanolfermentation process 207.

Referring again to FIG. 2 , the main ground corn stream rather than thewhole shelled kernel (as is the case for conventional wet or dry millcorn-to-ethanol fermentation processes) is now the input for thefractionation or whole corn grinding operation 207, which may be, forexample, a conventional wet milling operation or a dry milling operation207 a. The output 207 b of the fractionation or corn grinding operation207 a can be sent on for further processing 207 c (such as fermentationinto sugar to produce ethanol or other bio-chemicals).

In some embodiments, the grind rate of the grinding operation 207 a isincreased relative to a conventional grinding operation in which wholeshelled corn is the feedstock, rather than the ground corn stream, tocounteract the loss of starch separated into the high purity starchstream. Because increasing the grind rate may also lead to an increasedamount of non-starch components, which may take up volume and cut downon production in a fermentation process, in some embodiments, processesaccording to the disclosure may include additional separation steps toremove non-starch components. For example, the process may utilize themulti-step initial separation process 206 a, 206 b to remove fiber. Insome embodiments, the non-starch components resulting from the increasedgrind are processed and sold, for example to offset costs of starchremoval.

In some such embodiments, the additional separation step 206 b removesan amount of fiber to balance the fermentable to non-fermentable ratioback to what it would have been had the high purity stream not beenremoved. In further such embodiments, up to about 5% of the corn rate,which has a low starch percentage (for example less than about 15%starch on a dry basis), is removed to balance the fermentable tonon-fermentable ratio. In some embodiments, increasing the grind ratewhile balancing the fermentable-to-non-fermentable component ratio willmaintain production capacities (e.g. ethanol production) at a levelconsistent with the original process (i.e. the process using whole cornrather than the ground corn as input to the wet or dry millcorn-to-ethanol fermentation process). In some embodiments, non-starchcomponents resulting from the increased grind rate or are otherwiseseparated out from the main stream and may be processed and/or sold tooffset costs of starch removal.

As a person of skill should be able to understand from reading thisdisclosure, in some embodiments, the methods and systems according tothis disclosure enable production of a quantity of high purity starchstream with limited capital investment as compared to traditional starchproducing systems and limited or no loss of downstream production. Forexample, in some embodiments, the systems include only a limited numberof additional pieces of equipment for performing the functions describedherein.

A number of embodiments have been described but a person of skillunderstands that still other embodiments are encompassed by thisdisclosure. It will be appreciated by those skilled in the art thatchanges could be made to the embodiments described above withoutdeparting from the broad inventive concepts thereof. It is understood,therefore, that this disclosure and the inventive concepts are notlimited to the particular embodiments disclosed, but are intended tocover modifications within the spirit and scope of the inventiveconcepts including as defined in the appended claims. Accordingly, theforegoing description of various embodiments does not necessarily implyexclusion. For example, “some” embodiments or “other” embodiments mayinclude all or part of “some”, “other,” “further,” and “certain”embodiments within the scope of this invention. Methods and deviceswithin the scope of the disclosure can also be defined in accordancewith the below embodiments.

Non-inclusive additional embodiments:

1. A process, comprising: processing corn to produce a first high-starchcomposition comprising soft endosperm and at least about 88% starch on adry basis and a second feedstock composition comprising hard endospermsuitable for further processing in a corn dry mill or corn wet milloperation.

2. A process according to embodiment 1, wherein processing corncomprises milling the corn to facilitate separation of soft endospermfrom hard endosperm, and separating the soft endosperm from hardendosperm resulting in the first high-starch composition comprising softendosperm and the feedstock composition comprising the hard endosperm.

3. A process according to claim 1 or 2, further comprising producing atleast one of ethanol or a bio-based chemical from the feedstockcomposition in a corn fermentation facility.

4. A process according to any of embodiments 1-3, wherein the feedstockcomposition further comprises bran and germ.

5. A process according to embodiment 4, wherein the feedstockcomposition is directed to a fractionation process or a whole corngrinding operation.

6. A process, comprising:

-   -   a. pretreating corn to produce a first stream which facilitates        separation of soft endosperm from other components of the corn;        and,    -   b. separating a second, high-starch stream comprising soft        endosperm and at least about 88% starch on a dry basis from the        first stream, resulting in a third stream suitable for use as        feedstock in dry mill or wet mill corn fermentation processes.

7. A process according to embodiment 6, wherein pretreating comprisesmilling the corn.

8. A process according to embodiment 7, wherein up to about 50% of thefirst stream is in high starch form, comprising at least about 88%starch on a dry basis.

9. A process according to embodiment 7, wherein 50% of the first streamis in high starch form.

10. A process according to any of embodiments 6-9, wherein the secondstream is substantially free of hard endosperm.

11. A process according to any of embodiments 6-9, wherein the secondstream consists essentially of soft endosperm.

12. A process according to any of embodiments 6-11, wherein pretreatingresults in the soft endosperm having an average particle sizesufficiently smaller than the other components of the whole corn topermit separating the soft endosperm from the other components.

13. A process according to embodiment 12, wherein pretreating results inthe soft endosperm having an average particle size of about 500 micronsor less.

14. A process according any of embodiments 6-13 wherein pretreatingcomprises milling the corn with a pin mill.

15. A process according to any of embodiments 6-14, further comprisingdirecting the feedstock stream to a wet mill or dry mill ethanolfermentation facility and producing at least one end product from thethird, feedstock stream chosen from ethanol and a bio-based chemical.

16. A process according to any of embodiments 6-15, further comprisingfractionating the feedstock stream into an endosperm composition, a brancomposition and a germ composition.

17. A process according to any of embodiments 6-16, wherein the wholecorn is optionally cleaned, optionally tempered, or both prior topretreating.

18. A process according to any of embodiments 6-17, wherein thehigh-starch stream has a purity of at least about 90% starch on a drybasis.

19. A process according to embodiment 18, wherein the high-starch streamhas a purity level of at least about 94% starch on a dry basis.

20. A process according to embodiment 15, wherein: the third, feedstockstream has a reduced amount of starch as compared to a feedstock streamfor which soft endosperm has not been removed; the dry-milling orwet-milling process comprises using a grind rate that is increasedrelative to a similar corn fermentation process using feedstock forwhich soft endosperm has not been removed and that at least partiallyoffsets reduction in end product as a result of the reduced amount ofstarch.

21. A process according to embodiment 20, further comprising removing atleast a portion of additional non-starch components produced as a resultof the increased grind rate.

22. A corn-to-ethanol fermentation system, comprising:

-   -   a. a dry mill or wet mill ethanol fermentation system which        produces beer from feedstock sugars derived from a hard        endosperm stream; and,    -   b. a bolt-on pretreatment system configured to produce the hard        endosperm stream and a high purity starch stream derived from        soft endosperm, wherein the high purity starch stream comprises        at least about 90% starch on a dry weight basis.

What is claimed is:
 1. A process for producing starch streams in a drymill ethanol fermentation facility, the process comprising: (a) drymilling corn grain to produce a milled stream, wherein the milled streamcomprises starch, fiber and germ; (b) downstream from dry milling,separating starch into a first stream, wherein the separating forms asecond stream comprising fiber, germ and starch; (c) providing the firststream to a non-ethanol process, wherein the non-ethanol processcomprises producing one or more non-ethanol bio-products from starch inthe first stream; and (d) exposing at least a portion of the starch, thefiber, and the germ from the second stream to fermentation conditions toproduce ethanol from starch.
 2. The process of claim 1, furthercomprising: (a) saccharifying starch in the second stream into sugar;and (b) fermenting sugar in the second stream into ethanol.
 3. Theprocess of claim 2, wherein saccharifying is performed beforefermenting.
 4. The process of claim 2, wherein saccharifying andfermenting are performed simultaneously.
 5. The process of claim 2,further comprising processing the second stream through a grindingoperation prior to saccharifying starch into sugar.
 6. The process ofclaim 1, further comprising processing starch in the first stream intosugar.
 7. The process of claim 6, wherein processing starch in the firststream comprises: enzymatically hydrolyzing starch into one or moredextrins; and enzymatically hydrolyzing one or more dextrins into one ormore sugars.
 8. The process of claim 2, further comprising: distillingethanol to form whole stillage; separating thin stillage from wholestillage; and evaporating water from thin stillage to form syrup.
 9. Aprocess according to claim 1, wherein the first stream comprises up toabout 50% of the soft endosperm in the corn.
 10. A process according toclaim 1, wherein dry milling results in at least a portion of softendosperm having a size of 500 microns or less to facilitate separatingthe portion of soft endosperm from the corn grain by size.
 11. Theprocess of claim 1, wherein dry milling comprises milling corn grainwith a pin mill.
 12. The process of claim 1, further comprising: a)saccharifying starch in the first stream into sugar; and b) aftersaccharifying starch in the first stream, producing one or morenon-ethanol bio-products.
 13. The process of claim 1, wherein the firststream comprises at least 88% starch on a dry basis.
 14. The process ofclaim 1, wherein the first stream comprises at least 90% starch on a drybasis.
 15. The process of claim 1, wherein the first stream comprises atleast 94% starch on a dry basis.
 16. The process of claim 1, whereinproducing one or more non-ethanol bio-products from starch in the firststream comprises refining the first stream to increase purity of starchin the first stream, and wherein the one or more non-ethanolbio-products comprise starch.
 17. The process of claim 1, whereinproducing one or more non-ethanol bio-products from starch in the firststream comprises providing the first stream to a fermentation process toproduce a non-ethanol bio-chemical, wherein the one or more non-ethanolbio-products comprise the bio-chemical.
 18. The process of claim 1,wherein the one or more non-ethanol bio-products comprise starch. 19.The process of claim 1, wherein the one or more non-ethanol bio-productscomprise one or more non-ethanol bio-chemicals produced viafermentation.
 20. The process of claim 1, wherein the one or morenon-ethanol bio-products comprise sugar.